Gaskets and gasket-like devices with fasteners

ABSTRACT

A gasket-like device includes an elongated core, an outer jacket woven and preferably braided around and along the core and a plurality of individual fasteners spaced along the device, each fastener including a base captured between the core and the outer jacket and an engagement portion extending outwardly from the base through the outer jacket. An outer covering of plastic or other material may be applied, if desired, around and along part or all of the outer jacket.

FIELD OF THE INVENTION

The invention relates to gaskets and gasket-like devices such asweatherstrips, molding and the like and, in particular, to such deviceshaving integral fasteners for attaching the device to a support.

BACKGROUND OF THE INVENTION

The doors of many appliances such as refrigerators, ranges, microwaveovens, etc. typically have a flexible, tubular gasket around theirperimeter for sealing and a variety of other reasons. Previously, suchdoors have been fabricated by joining together front and back pieces.This has enabled the door manufacturers to use gasket assemblies whichinclude a pair of joined, parallel, elongated cylindrical members. Onemember was then either pushed through a slot or slots provided on the"back" piece of the door or wound around the perimeter of such a backpiece which was then fitted into a receiving cavity in the "front" pieceof the door. An exposed cylindrical member formed the gasket while aremaining cylindrical member, hidden within the door, held the gasketcylindrical member in place against the door.

The cylindrical members of these gasket assemblies often were formedfrom a knitted, metal wire tubular cores covered with braided, glassfiber jackets.

There has been a desire on the part of appliance manufacturers todevelop a one-piece door construction in such appliances to reducefabrication costs. Gaskets would have to be attached to such doors froman exterior side using some type of mechanical fastening.

One approach for mechanically mounting such gaskets to one-piece doorshas been to provide a flexible, hollow cylindrical gasket with clip-typefasteners protruding along one side thereof. Such gaskets have beenformed from a hollow, tubular, knitted wire core and braided, glassfiber outer jacket, somewhat similar to the cylindrical members of theold gasket assemblies. After fabrication, a wire member, bent at severallocations along its length to form a series of connected clip members,is inserted into the hollow center of the tubular wire core and the bentportions of the wire pressed through the wire core and surroundingfabric jacket by hand.

There are several drawbacks to such gaskets. First, they requireconsiderable hand labor to assemble. Second, the wire has to be passedthrough the inner core and outer jacket without damage to either. As aresult, the wire used must be fairly thin and the clip portions tend tobe easily damaged. Third, because the wire must be inserted into thegasket after the gasket has been made, assembly becomes more cumbersomeand difficult as gasket lengths are increased. The fabrication ofsignificant continuous lengths of undamaged, unflawed gasket with thewastage which would be involved would be prohibitively expensive.

In addition to the foregoing limitations, the thin wire which must beused to enable the clip portions to be pressed through such gaskets doesnot provide a significant spring force for firmly attaching the gasketto the door or other mounting member. Because the thin wire is extremelyflexible and does not trap any significant area of the gasket betweenitself and the door or other mounting member, it does little to preventthe gasket from rolling to either side of the attachment points orbending between the attachment points.

It would be beneficial to provide flexible gaskets with protrudingfasteners for mounting to appliance doors and other members which can beattached to the doors or other members as firmly as desired.

It further would be beneficial to provide flexible gaskets withprotruding fasteners in which the gaskets do not tend to roll aroundsuch fasteners.

It further would be beneficial to provide hollow, tubular gaskets withthe aforesaid characteristics for light weight and durability.

It further would be beneficial to provide gaskets and other gasket-likedevices with the foregoing characteristics in a form which furtherincludes a plastic and/or rubber outer covering along at least someportion of the device.

It further would be beneficial to provide continuous, elongated gaskets,and gasket-like devices such as molding, etc., with embedded, protrudingfasteners which exhibit superior mounting stability.

SUMMARY OF THE INVENTION

The aforesaid beneficial results and others are achieved by myinvention.

In one aspect, the invention is an elongated, gasket-like devicecomprising an elongated core; a woven outer jacket surrounding the coreand extending along the core; and a plurality of fasteners spaced alongthe device, each fastener having a base captured between the core andthe woven outer jacket and each fastener further having an engagementportion extending outwardly from the base through the outer jacket.

In another aspect, the invention is the method of making an elongatedgasket-like device with at least a plurality of spaced fasteners, eachfastener including a base and an engagement portion extending from thebase, which comprises the steps of weaving an outer jacket around anelongated core member and capturing the base of each of the plurality offasteners along the device between the core and the outer jacket beingwoven with the engagement portion of each fastener protruding outwardlythrough the woven outer jacket.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofpreferred embodiments of the invention will be better understood whenread in conjunction with the appended drawings. For the purpose ofillustrating the invention, there is shown in the drawings embodimentswhich are presently preferred. However, it should be understood that theinvention is not limited to the precise arrangements andinstrumentalities shown. In the drawings:

FIG. 1 is a perspective, diagrammatic, partially-sectioned view of apreferred embodiment of a gasket-like device of the invention;

FIG. 2 is a diagrammatic, transverse, local cross-sectional view of thedevice of FIG. 1 along the lines 2--2;

FIG. 3 is a diagrammatic, longitudinal, local cross-sectional view ofthe device of FIGS. 1 and 2 along the lines 3--3;

FIG. 4 is a diagrammatic, perspective view of a preferred clip;

FIG. 5 is a diagrammatic view of a braiding machine configured tofabricate the devices of the subject invention in the preferred mode;

FIG. 6 is a diagrammatic, perspective, partially-sectioned view of agenerally planar embodiment of the invention; and

FIG. 7 is a transverse, cross-sectional view of the embodiment of FIG. 6along the lines 7--7.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings, wherein like numerals are employed for theindication of like elements throughout, there is shown in FIGS. 1-3, afirst preferred embodiment gasket-like device 10 of the invention.Referring to FIG. 1, the basic, essential components of the device 10include an elongated core 12, a surrounding woven outer jacket 16 and aplurality of individual fasteners 20. The core 12 is preferably acontinuous, flexible, cylindrically-shaped, tubular member preferablyknitted from a plurality of stainless steel wires 14 in a conventionalfashion. The core 12 is shown in FIG. 1 as extending from one end of thedevice 10 for clarity. A woven outer jacket 16 surrounds and extendsalong the core 12. Preferably the jacket 16 is braided from amultiplicity of glass fiber yarns 18. Spaced at predetermined intervalsalong the device 10 are a plurality of individual preferred springclip-type fasteners 20.

One such clip 20 is shown separately in FIG. 4. As can be seen in thatfigure, the clip includes a base 22 and an engagement portion 24integral with the base 22 and extending substantially perpendicularlyfrom one side thereof. The base 22 is substantially elongated between apair of opposing ends 26 and 28 each of which is substantially roundedprimarily to prevent cutting of the outer jacket 16. The engagementportion 24 of each clip includes a pair of adjoining, resilientlyflexible spring arms 30 and 32 which can be compressed against oneanother to enable the arms to pass through an opening in the member towhich the device 10 is attached and then return to their original,depicted configuration thereby securing the device to the member by aninterference fit. As is best seen in FIG. 2, the base 22 of each clip 20is captured between the core 12 and the outer jacket 16 with theengagement portion 24 extending outwardly from the base 22 through theouter jacket 16.

The basic device 10 formed by the core 12, woven outer jacket 16 andclip-type fasteners 20 can be used as a gasket in a conventional ovendoor.

The subject invention enjoys several advantages over the existing art.First, the engagement arms 30 and 32 of the clips 20 do not have to beof the same diameter or width as the base. Indeed, as is shown withrespect to the clip 20 of FIG. 4, the engagement arms 30 and 32 are cutfrom the central portion of the base 22 which is much larger than eitherof the arms 30 and 32. The enlarged base allows a greater area of theouter jacket 16 to be trapped between the base 22 of the clip 20 and themember receiving the engagement portion 24 of the clip 20. This reducesthe tendency of the device 10 to roll around the engagement point andresults in a more securely fastened device 10.

The depicted clips 20 may be formed by stamping from a planar sheet ofmetal. However, other type clips and other fasteners of a wide varietyof constructions and materials including plastic, composite plastic andmetal, etc. can be used if suitable for the use to which the device ismade. Moreover, since a variety of clips or other types of fasteners canbe employed, the configuration of the engagement portion 24 and base 22can be varied and the engagement force developed by the engagementportion 24 selected from a potentially wide range of attachment forceswhich can be achieved. The base 22 might be slightly longitudinallycambered as indicated to maintain the engagement portion 24 undertension when installed, thereby preventing movement between the clip 20and the member receiving the clip. The base also can be camberedtransversely or otherwise shaped in any desired way to optimize seatingof the fastener against the receiving door or other member.

Fabrication of the device 10 is straightforward. The preferred, knittedwire core 12 is conventional, and its manufacture is known to those ofordinary skill in this art. Also, it is described at least to someextent in U.S. Pat. No. 3,578,764 incorporated herein by reference inits entirety. That patent discloses the beneficial uses of including aheat-resistant, flexible knitted metal wire core and a flexible,heat-resistant fabric jacket or cover, preferably of glass fibers, foruse as an oven door gasket. Conventional elongated, tubular knitted wiremembers can be obtained from such distributors as Montgomery Co.,Windsor Locks, Conn. and ACS Industries, Woonsocket, R.I. A flexibleknitted wire core 12 for an oven door gasket might be made of 7 mil,full hard 304 stainless steel wire in a continuous jersey knit having 12wales and 13±1 courses/inch to form a continuous knit,cylindrically-shaped, hollow tube approximately 1/2 inch in diameter.The specification for a wire knitting machine to knit a hollow wire corelike the core 12 would be 7/8 inch cylinder, 12 needles, 18 gauge,circular jersey knitting machine.

The method of providing the braided outer jacket 16 capturing the base22 of the clip fasteners 20 against the core 12 is also straightforward.FIG. 5 depicts diagrammatically significant portions of a conventionalbraiding machine 40 which includes a base 42 mounting a multiplicity ofspindles 44. Each spindle 44 receives a separate bobbin 46 of yarn 18.Only a few of the spindles 44 and bobbins 46 are depicted for clarity.The spindles 44 and bobbins 46 are driven along tracks (not depicted) inthe base 42 in a weaving, maypole fashion so as to braid a continuoustubular outer jacket 16 around the core 12.

Such braiding machines can be obtained from a variety of commercialsources including Wardwell Braiding Machine Company, Central Falls, R.I.and Braider Manufacturing Company-Kokubun, Inc., Nakajimacho, Hamamatsu,Japan. The typical specification for such a machine is a 72 carrierbraider, No. 2 butt, 36×100 gear ratio with 24 inch capstan. The typicalspecification for such a braided jacket might be, for example, 72 endsof yarn (fiberglass) size-150's, 10 count, 20±1 picks per inch.

The core 12 of the device 10 is fed through the center opening 48 in thebase 42. The machine 40 thereupon braids the yarns 18 into the outerjacket 16 extending around and along the length of the core 12. Normallyin such machines, the core 12 would be fed upward and the fastenersinserted upwardly between the ascending core 12 and a cone formed by themultiplicity of yarns 18 being laid over that core 12 until some portionof the base 22 of the clip fastener 20 is captured by the yarns 18 andheld against the core 12.

To assist in positioning the clips 20 or other fasteners, the braider 40may be modified in a known matter depicted diagrammatically in FIG. 5 toadd a central reversing ring 50 which enables the core 12 to be fedvertically downward, rather than upward, through the machine 40. Thering 50 is supported by a pair of arms 52 and 54 attached to a crosspiece 56 fixedly supported in the central opening 48 of the base 42. Inthis way, a funnel 58 formed by the yarns 18 converging on the core 12tapers downwardly onto the core 12, permitting the clips 20 or otherindividual fasteners to be inserted downwardly among the convergingyarns 18 from above, as depicted. This simplifies, to some extent, thefeeding and positioning of the individual fasteners.

After braiding, the glass fiber outer jacket 16 of the device 10 can beheat treated and/or colored, if desired, in a conventional fashion.

FIGS. 6 and 7 depict another preferred embodiment of the invention inthe form of a generally flat, elongated, continuous, gasket-like device60 with a multiplicity of clip fasteners 20 protruding from one sidethereof. The device 60 includes in addition to the clips 20, asubstantially planar, elongated core 62 and a surrounding planar wovenouter jacket 64. The jacket 64 can be braided using a conventionalbraiding machine, like those previously identified, with salvage bars asare conventionally used on such machines to provide a substantiallyplanar braided jacket 64 around the planar core 62. The planar core 62could be formed by flattening a tubular knitted wire core like core 12of the device 10. Other flexible, planar elongated members of fabric,plastic, metal or the like alternatively could be used.

Referring back to FIGS. 1-3, the basic device 10 already described caninclude, in addition to the core 12, surrounding outer jacket 16 andfasteners 20, at least one outer covering 72 over some or all of theouter jacket 16. This covering 72 is sectioned back in FIGS. 1-3 toreveal the outer jacket 16 and core 12 of the basic device.

As indicated, the preferred outer covering 72 is a layer formed from anyof a variety of plastic compositions, applied in conventional ways tothe outer jacket 16 of the device 10. In particular, an outer coveringlayer 72 of an elastomer such as silicone rubber can be applied to theouter jacket 16 by such conventional methods as low-pressure extrusionor dipping to provide a flexible, gasket-like device which provides airand/or weather tightness and would be ideally suited for use withappliances such as dryers Also, conductive polymers such as silverfilled silicone might be employed as the outer covering layer 72 forusing such devices to provide RF shielding and/or EMI shielding.Silicone rubber in particular is a preferred material for use as anouter covering due to its relatively high temperature performance, waterresistance and long service life.

The outer layer 72 is depicted as circumferentially surrounding andextending along the outer jacket 16 of the device 10. However, it isunderstood that in certain applications, it may be advantageous to coverthe outer jacket 16 with a covering which extends only partially aroundthe circumference of the outer jacket 16 such as, for example, in thefabrication of a molding strip having a plastic finished side. In suchcases other fasteners (not depicted) may be inserted, if desired,between the core and outer jacket, for example, on a side of the device10 opposite the indicated fasteners 20, to partially protrude throughthe jacket and provide attachment points for the plastic outer layer.Also, in certain applications, the outer covering layer 72 may beextended only along a portion of the length of the device 10 or berepeated at intervals along the continuous length of the device 10.

The use of the disclosed devices 10 and 60 would be in a conventionalfashion by inserting the clips 20 or other provided fasteners intoholes, mating members or other suitable receptacle in a door or otherreceiving structure.

The devices of the subject invention enjoy considerable advantages overexisting gaskets and gasket-like devices formed by the insertion of abent, continuous wire through the various layers forming the device toprovide fasteners. In particular, the devices of the subject inventioncan be made using solid as well as hollow cores, as is illustrated bythe embodiment of FIGS. 6 and 7. Devices of the subject invention arenot as likely to be damaged during fabrication, such as by deforming ofthe engagement clips or tearing of the core or outer jacket. Withinreasonable limits, any desired attachment force can be provided by theselected use of clips of different sizes, materials, configurations,etc. and possibly other types of fasteners. Greater attachment forcescan easily be achieved because larger clips, for example, can beemployed. Moreover, different clips and fasteners can be used along thesame device to provide greater versatility in attachment. There is lesstendency of the device to move after attachment as it can be firmlysecured between the base of each of the fasteners and the door or otherstructure receiving the fastener. Moreover, the base can be configuredto some degree, if desired, to conform to the surface of the door orother receiving structure.

It will be appreciated that devices of the subject invention can beprovided in a wide variety of sizes. While knitted wire is preferred asthe core material for strength, flexibility, light weight andtemperature resistance, other types of hollow and solid cores and corematerials can be used. While glass fiber yarn wearable is the elementmaterial preferred for the outer jackets 16 and 64 for the same reasons,natural and polymeric materials could be used. Indeed, it is conceivablethat even metal wire might be desired as the outer jacket weavableelement material in some applications. In addition to the describedsilicone materials, other materials including but not limited to roomtemperature vulcanizing rubbers and conventional polymeric materialsmight be applied around and/or along part or all of the outer jackets 16or 64 of the devices of the invention by conventional means including,in addition to those already mentioned, injection molding. Suchpolymeric materials also might be hard curing rather than elastomeric.Also, true rubbers and other types of coverings may be employed over theouter jacket.

While various embodiments of the invention have been disclosed, andmodifications thereto suggested, it will be recognized by those skilledin the art that changes could be made to the above-described embodimentswithout departing from the broad, inventive concept thereof. It isunderstood, therefore, that this invention is not limited to theparticular embodiments disclosed, but is intended to cover anymodifications which are within the scope and spirit of the invention, asdefined by the appended claims.

I claim:
 1. A method of making an elongated gasket-like device with atleast a plurality of spaced fasteners, each fastener including a baseand an engagement portion extending transversely from the base,comprising the steps of:weaving an outer jacket of weavable elementsaround an elongated core; and inserting separate, unconnected,individual fasteners between the core and the weavable elements beingwoven around the core with the engagement portion of each fastenerfacing away from the core and towards the weavable elements, theweavable elements capturing the base of each inserted fastener againstthe core between adjoining portions of the core and the outer jacketbeing woven wherein each fastener base is irremovably retained betweenthe adjoining portions of the core and outer jacket with the engagementportion of each fastener protruding outwardly through the woven elementsof the adjoining portion of the outer jacket.
 2. The method of claim 1wherein the weaving step comprises braiding the outer jacket around andalong the core.
 3. The method of claim 1 wherein said elongated corecomprises a hollow tube of knitted metal wire
 4. The method of claim 1wherein the outer jacket comprises a braided sleeve of glass fiberyarns.
 5. The method of claim 1 further comprising the step of providingan outer covering on at least a portion of the outer jacket.
 6. Themethod of claim 5 wherein the outer covering comprises a silicone layer.